Method and apparatus for pre-fabricating a synthetic sports field

ABSTRACT

A method of prefabricating and installing a synthetic turf field includes providing a controlled manufacturing facility with an open area that allows a plurality of turf strips to be laid out on a floor thereof. Visual markings are placed on the floor to allow the individual strips to be properly aligned on the floor. Once aligned, inlays can be placed into the proper strip and then secured. After the inlays have been secured, the strips can be rolled up and appropriately labeled for subsequent installation. After all the strips that will make up the field have been processed and rolled up, the rolls can be taken to the job site so the field can be installed.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority from U.S. Provisional PatentApplication Ser. No. 61/027,140, entitled “Synthetic Turf FieldPre-Fabrication”, which was filed on Feb. 8, 2008, and is herebyincorporated by reference as though set forth fully herein.

TECHNICAL FIELD

The present application relates generally to synthetic turf systems.More particularly, the present invention relates to a method ofprefabricating a synthetic turf system for subsequent installation.

BACKGROUND OF THE INVENTION

Methods for installing synthetic fields are well-known. As is wellknown, the installation method is primarily a manual process andtypically differs from field to field. Most synthetic fields include aplurality of strips of synthetic turf that are placed or laid out on asubstructure or sub-base, such as the ground, upon which the field ispermanently installed. The strips together make up a completed syntheticfield after they have been laid out, processed and then secured. Some orall of the strips of synthetic turf typically require markings thereon,such as yard line markings, numbers or the like. When the fields areinstalled, some of the markings, such as logos, yard line numbers, andhash marks are inserted into the field after it has been placed on thesub-base at the location where the field is to be permanently located.As can be appreciated, the position of each individual strip withrespect to the overall synthetic field is important. Similarly, thelocation of the markings on each of the individual strips is critical tothe overall appearance of the field. If the markings are inserted in thefield improperly, they can be out of alignment with respect to the othermarkings on the field or can be individually crooked, which can make thefield look sloppy.

Due to the nature of these fields, their construction, and the nature ofthe steps required for their installation, the typical manufacturing andinstallation steps suffer from a variety of disadvantages, includingthose discussed above. Also, the fabrication, manufacturing andinstallation steps are extremely time consuming and labor intensive.Further, these steps can be extremely variable from field to field aswell as costly due to the extensive labor commitment required.

SUMMARY OF THE INVENTION

It is therefore an advantage of the present invention to provide amethod or process that reduces the inherent variables that exist withinstalling synthetic turf fields.

It is another advantage of the present invention to reduce or minimizethe inherent variables that exist with installing synthetic turf fields,which can negatively affect the quality, cost, and/or appearance ofthese fields.

It is a further advantage of the present invention to provide a processor method that improves the quality of the manufacturing as well as theinstallation of synthetic turf fields.

It is still a further advantage of the present invention to provide aprocess or method that decreases the cost associated with themanufacturing as well as the installation of synthetic turf fields.

It is still another advantage of the present invention to provide aprocess or method that decreases the time required for the manufacturingas well as the installation of synthetic turf fields.

It is yet a further advantage of the present invention to provide aprocess or method of installing a synthetic turf field that providesmore uniformity than prior methods and minimizes the inherent variablesthat can exist from field to field.

In accordance with the above and the other advantages of the presentinvention, a method of prefabricating and installing a synthetic turffield is provided. The method includes the steps of laying the field outin a controlled manufacturing facility by placing a plurality ofindividual strips of turf onto the facility floor such that the stripsare properly and correctly aligned for proper fabrication andinstallation of the complete field. The controlled manufacturingfacility is preferably an indoor facility. Thereafter, any inlays forthe pre-fabricated field are inserted into the applicable individualstrips at the appropriate place in the controlled manufacturing facilitysuch that they are in the proper location when the entire field issubsequently installed. The inlays can include, numbers, hash marks,arrows, and/or other ancillary field markings Obviously, other inlaysmay also be available for prefabrication such that they are alreadypresent in the strips when the field is installed.

Additionally, the processes in the manufacturing facility are preferablyunder controlled conditions for every field, thereby minimizingever-changing and unpredictable variables like weather, crew skilllevel, tools, and installation means and methods. Upon completion of theinlay insertion and other prefabrication steps, the individual stripsare rolled up and the plurality of rolls are transferred to theinstallation site. All of the necessary equipment to assist in theprefabrication process are located at the indoor facility Once thesynthetic turf rolls arrive at the installation site, the installationcrew will have less work to perform to complete the job because of theinstallation of the inlays during the pre-fabrication process.Accordingly, the time and cost associated with the on-site installationwill be reduced.

These and other features and advantages of the present invention willbecome apparent from the following description of the invention, whenviewed in accordance with the accompanying drawings and appended claims.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a partial perspective view of an indoor manufacturing facilityfor prefabrication of a synthetic sports field in accordance with apreferred embodiment of the present invention;

FIG. 2 is a schematic illustration of a floor of an indoor manufacturingfacility for prefabrication processing of a synthetic sports field withvisible markings thereon in accordance with a preferred embodiment ofthe present invention;

FIG. 3 is a schematic illustration of a plurality of strips of syntheticturf laid out on a floor of an indoor manufacturing facility forprefabrication processing in accordance with a preferred embodiment ofthe present invention;

FIG. 4 a schematically illustrates a template positioned on the backside of a strip of synthetic turf in accordance with a preferredembodiment of the present invention;

FIG. 4 b schematically illustrates a section of synthetic turf matchingthe outline of the template being removed from the strip of FIG. 4 a toallow insertion of a corresponding inlay in accordance with a preferredembodiment of the present invention;

FIG. 5 is a schematic illustration of the plurality of strips ofsynthetic turf of FIG. 3 after insertion of inlays into the strips inaccordance with a preferred embodiment of the present invention;

FIG. 6 is a schematic illustration demonstrating the installation of asynthetic turf field at its installation site in accordance with apreferred embodiment of the present invention; and

FIG. 7 is a schematic illustration of the installation process of asynthetic turf field in accordance with preferred embodiment of thepresent invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention relates to prefabricating a synthetic turf fieldfor later installation. More specifically, the present invention relatesto a method of prefabricating a synthetic turf field prior toinstallation at a different permanent location. The prefabricationprocess helps ensure accurate installation of the synthetic field in amore economic, consistent and cost effective manner. The prefabricationprocess also helps minimize or eliminate variables that may exist indifferent installations, including due to weather, crew skill level,tools, and installation methods. The steps of the method or process forprefabricating a synthetic turf field for subsequent installation aswell as the installation steps are discussed in connection with thepreferred embodiments described below with reference to the accompanyingfigures.

Referring now to FIG. 1, in accordance with a preferred embodiment ofthe present invention, a facility 5 is provided where the synthetic turffield is initially fabricated. The facility 5 is preferably a controlledfacility such as an indoor manufacturing facility, which is not thelocation where the synthetic field will be permanently installed. Thefacility 5 includes an open area with a substantially flat floor 10 onwhich the various components that will be used to make the syntheticfield can be laid out for prefabricating. It will be understood that thesubstantially flat floor 10 and the working area must be sufficientlylarge or of sufficient size to roll out or lay out the synthetic turfstrips that will be prefabricated and then utilized to make up the fullsynthetic turf field. It is also preferable that the facility has roomfor the other components that are used to make up the completedsynthetic field, including the various markings to be inlayed, asdiscussed in more detail below.

In one embodiment, an initial step of the prefabricating processincludes visually indicating on the floor 10 of the facility 5 certaindimensions corresponding to locations on the field. These visualindications will assist in the alignment, orientation, and sizing of theindividual synthetic strips. The dimensions are preferably markedpermanently on the floor 10. However, it will be understood that thevisual markings can be releasably secured or fixed to the floor 10 inthe event fields of different sizes or configurations requireprefabrication. For example, the hash marks for a professional footballfield are positioned in a different location than a college footballfield.

As shown in FIG. 2, a line corresponding to the centerline of the field(in the direction from one end of the field to the other) is preferablymarked on the floor 10 and is generally designated by reference number12. This line allows for alignment of each of the strips at a locationcorresponding to the center of the field. Also, lines corresponding tothe locations on the field where the hash marks are to be positioned arealso visually indicated or marked on the floor 10 and are generallyindicated by reference number 14. These markings 14 are preferablyintended to indicate a particular portion of the hash marks, such as aninner edge thereof (closest to the center of the field), which willensure accurate alignment. However, it will be understood that themarkings 14 could be positioned to align with the outer edge of themarkings etc. However, each of the lines 14 should be spaced an equaldistance from the centerline 12, as indicated by reference letters A.

Lines, generally indicated by reference number 16, are also placed onthe floor 10 at locations corresponding to positions on the field whereyard line numbers need to be located. Again, the markings 16 can bepositioned at an inner edge of the yard line numbers to assist in properalignment. Moreover, the markings 16 can be positioned to align withanother portion of the numbers, i.e., the outer edge. In any event, themarkings 16 should be spaced an equal distance from the centerline 12,as indicated by reference letters B. Further, the locations on the fieldwhere the outer hash marks are to be inserted are marked on the floor10, as generally indicated by the lines designated reference number 18.Again, the lines 18 can be located at the inner edges of the hash marks,the outer edges of the hash marks, or other suitable portions thereof.Again, the markings 18 are spaced an equal distance from the centerline12 as indicated reference letters C.

Similarly, the locations where the sidelines of the field are locatedare marked on the floor 10 with lines generally indicated by referencenumber 20. The lines 20 assist in properly aligning, sizing andorienting the field and are also spaced an equal distance from thecenterline 12, as indicated by reference letters D. It will also beunderstood that a variety of other dimensions could be marked on thefloor 10 to assist in prefabricating the field for subsequentinstallation. Further, more or fewer dimensions could be marked orotherwise placed on the floor 10 as required. Also, while a variety ofdimensions may be marked on the floor, they may not all be needed forthe prefabrication of any individual field. Moreover, the distance ofeach of the lines from the centerline 12 can vary as needed.

In addition to providing a facility 5 of sufficient size to roll out thesynthetic turf strips and marking certain dimensions corresponding tofield locations on the floor 10, the preferred embodiment includes othersteps for prefabricating a field for subsequent installation.Specifically, the facility 5 preferably has on hand and available allnecessary equipment to fabricate the field and complete theprefabrication processes. Thus, all necessary equipment required by theinstallers for fabricating the field is readily available and includes:(1) transports for moving the rolls of synthetic turf from one locationto another in the facility 5; (2) equipment for rolling out the rolls ofsynthetic turf onto the floor 10 for processing, and (3) equipment forrolling up the strips of turf into rolls. Additionally, the facility 5should have sufficient space on at least one end of the working area toallow for material transport such as to the installation site. Inaccordance with a preferred embodiment, sufficient working area isestimated to be in the area of at least thirty (30) feet.

Moreover, in accordance with a preferred embodiment, the facility spacewhere the synthetic turf will be worked on should be completely enclosedsuch that the temperature and climate can be maintained and controlled.Further, by keeping the work space completely indoors, the ability tocontrol inherent variables that result from climate change issignificantly enhanced. This configuration also assists in providinguniformity of field fabrication and installation. The facility shouldalso have available all templates to allow for cutting numbers, hashmarks, arrows and other ancillary markings that are required for thefield. It will be understood that other steps and equipment may also beutilized to assist in improving the fabrication process.

Once the facility 5 is available and includes the necessary equipmentand space, the prefabrication process of the field can be performed. Atthe outset, a plurality of rolls that together will form an entiresynthetic sports field are selected for the prefabrication process, suchthat the appropriate number of rolls of turf are on hand. Eachindividual roll consists of a discrete strip 22 of synthetic turf thatis positioned in the working area. The configuration of each strip in anunrolled position is well known and consists of a front side 24 and aback side 26. The back side 24 consists of a base material with rows oftufted yarn secured thereto and extending outwardly from the front side24 to form the synthetic turf surface. Each strip 22 also preferablyincludes a tufted line, generally designated by reference number 28,which is formed along the entire length of the roll (from one end to theother in a direction perpendicular to the centerline 12). The line 28represents a yard line, such as a five yard line (i.e. 5, 10, 15, etc.),is preferably colored white, and is about four (4) inches in width. Theyard line 28 is located adjacent one edge 30, 32 of each strip and whilethe line 28 extends from the front side 24, it is visible from the backside 26.

Each roll is positioned and oriented properly at one end of the workingarea before being rolled out and positioned on the floor 10 of thefacility 5. Once positioned, the strip 22 of turf should be unrolledwith the back side 26 up and the front pile side 24 down (up side down).When rolling out the strip 22 of turf, the grain of the turf ispreferably facing the starting point of roll-out. However, the grain ofthe turf could alternatively face against the starting point of roll-outas it is being unrolled. It will be understood that a variety of othersteps may be employed with respect to the roll selection and orientationsteps. Further, the configuration of the tufts is not critical to thepresent invention.

The process for rolling out each strip 22 of turf is now described belowin connection with FIG. 3. In accordance with one embodiment of thepresent invention, the selected strip 22 is rolled out across the widthof the working area. To do this, a portable roll-up machine 36, uponwhich the roll of turf is disposed, is moved to the location where thework will be performed and then it is unrolled. Each strip 22 can beeither unrolled manually or automatically. The entire length of thestrip 22 should be rolled out and the strip 22 is then centered on thecenterline 12. Also, once unrolled, the roll must be squarely aligned onthe floor 10 with respect to the visual markings. It is preferred that atest is employed to ensure that each strip 22 is square with respect tothe centerline 12. An exemplary test for ensuring this alignment is a6-8-10 Pythagorean test. However, other suitable tests may also beemployed. To be in alignment, the edges 30, 32 of each strip ofsynthetic turf are oriented perpendicular to lines 12, 14, 16, and 18.Once properly aligned and confirmed, the centerline 12 from the floor ismarked on the back side 26 of the turf with permanent marking to assistin alignment of each strip 22 at the location of permanent installation,as generally designated by reference number 12′. It will understood byone of ordinary skill in the art that other steps may also be performedas is deemed necessary. The other markings from the floor can also beplaced on the back side 26 of the strip 22 as necessary.

In addition to making available the strips to roll out and fabricate,the tufted inlays are also located in the facility. The inlays can allbe located on a single strip of material such that they need to be cutout for subsequent insertion on the field. For example, a set of yardline numbers can be tufted in white on a single piece of backingmaterial, such as generally indicated by the strip 38. It will also beunderstood that this strip 38 can have a variety of other numbers formedthereon. Alternatively, the inlays can be formed separately andindividually. The backing material of the strip 38 should match or atleast be compatible with the backing material for the remainder of thefield. Also, the inlays for the hash marks are also tufted onto a pieceof backing material, such as generally indicated by reference number 40.The hash marks are preferably formed in unbroken parallel lines to allowfor subsequent cutting. Alternatively, they can be individually formedin the proper length. Any other indicia should be similarly formed. Itwill be appreciated that other ways of forming any necessary inlays mayalso be employed.

Once the line 12′ has been marked or disposed on the back side 26 of theturf, any indicia, lines or other field markings can then be insertedinto each strip 22. To accomplish this, the necessary templatescorresponding to the appropriate inlays to be inserted into each stripare gathered from within the facility. Next, one of the templates ispositioned on the back side 22 of the turf in the proper location forprocessing. For example, with reference to FIG. 4 a, a template 50 inthe shape of the number to be inserted in the selected strip is gatheredand then placed on the back side 26 of the turf in the properorientation. The template 50 is then secured in place on the back side26 of the turf. Using a suitable cutting tool, a hole is then madethrough the turf backing around the perimeter 52 of the template 50,such that a cut is made in the strip 22 in the shape of the inlay to beinserted. The cut out is then removed from the strips 22, as shown inFIG. 4 b. The removable cut out is then placed to the side as scrap.This step is then repeated for all of the markings that are to beinserted into each strip 22 of the field 10. The obvious differencebetween subsequent processes is that the shape of the template will varydepending upon the inlay to be inserted into the field. Other steps mayalso be performed as needed.

Once the holes corresponding to the templates 50 as well as the items tobe inserted into the field have been formed, the next step is then toadhere the inlays to the field. Specifically, the numbers, the hashmarks, the arrows and/or other ancillary markings are gathered forinsertion into the created openings to form a part of the final field.Prior to adhering the necessary inlay to each individual strip, itshould be ensured that the construction of each inlay matches theconstruction of the strip 22 into which it is going to be inserted. Thetemplate 50 should also be removed from the back side 26 of the turf.Next, the appropriate adhering mechanism, such as seam tape, adhesive,and/or other applicator tools are gathered. Thereafter, the inlay isinserted into the matching inlay opening formed in the strip 22. Theinlay is then secured to the strip 22 by glue or another appropriateadhering method. These steps should be repeated for all inlays on eachstrip until all inlays for the field have been inserted. It will beappreciated that other suitable steps may also be performed as required.

After each inlay has been inserted into the strip 22, the adhesive usedto secure the inlay to the strip 22 must be allowed to cure for asufficient number of hours. The curing time may obviously vary dependingupon the type of adhesive used. While the adhesive is curing, the strip22 in which the inlay has been secured should remain untouched in itsflat position. Also, weight may also be applied to the inlay tofacilitate curing.

FIG. 5 illustrates a plurality of strips 22 after the prefabricationprocess has been completed. As shown, the strips 22 have been cut suchthat each end 56 thereof is aligned with the side line 20. Also, thestrips 22 are positioned such that the centerline 12 bisects each strip22. Further, the inlays have been inserted and are aligned with theirrespective lines 14, 16, and 18. The strips 22 are still upside down andcan now be rolled up. Thereafter, the portable roll-up mechanism 36should be positioned at the proper end 56 of the strip 22. The core(center for each strip 22 when rolled-up) is attached to the portableroll-up mechanism 36. The strip 22 is then secured to one end of theroll-up mechanism 36 and rolled up around the core. Once each strip 22has been rolled-up around its respective core, it is then placed in abag or other suitable retention mechanism and labeled according to aseaming diagram to facilitate staging during installation. The rolls arethen ready for shipping and installation at the job site.

Referring now to FIG. 6, which illustrates an exemplary installation ofa synthetic field in accordance with a preferred embodiment of thepresent invention. The first step in the installation process is toensure that the base or sub-base upon which the field will be installedis certified for installation. Next, all markings for the field areprecisely placed on the top surface of the base, with a suitable markingsuch as paint. This will assist in properly aligning the strips. Thecenterline of the field is then marked on the sub-base from goal post togoal post, as generally shown by line 70. The line 70 is necessary foralignment of the strips 22 and inlays for prefabricated fields. Thecenter of the field is intended to match the centerline 12 on the floor10 of the facility 5.

In accordance with the preferred embodiment, the next step in theinstallation process is to square off the center of the field andidentify the location of the fifty (50) yard line. The midfield line isthen marked on the sub-base as generally indicated by reference number72. Also, the individual yard line markings are marked on the sub-base60 such they are perpendicular to the centerline of the field 70. Next,the yard lines need to be marked from one side of the field to the otherside of the field. A set off is required to line up the edge of thestrip 22 having the white yard line. This set off is preferably abouttwo (2) inches. Next, every five yards from the fifty (50) yard line toeach end zone are marked on the sub-base 60, as generally indicated byreference number 74. Additionally, the sidelines are marked on the fieldin the proper location.

With reference to FIG. 7, the first step of the installation processinvolves placing the first roll at the fifty (50) yard line and thewhite yard line of that roll is lined up with the midfield marking 72 onthe sub-base 60. Additionally, the centerline 70 of the sub-base isaligned with the centerline 12′ marked on the back side 26 of the strip22. Next, the other strips 22 are rolled out in the appropriate orderbased on the inlaid yard line markings and laid out on the sub-base 60.Once several strips 22 have been rolled out and aligned, in accordancewith the preferred embodiment, the markings are rechecked to ensurealignment before the midfield strip is secured with spikes or othersuitable securing means to hold the piece in place. Once the strips 22are aligned, the seams of the strips 22 are cut and secured, such as bygluing or securing, in accordance with known industry standard methods.Lastly, the side lines can be installed in accordance with knownmethods. This results in an installation process that is less costly,more accurate and requires less time to complete.

While particular embodiments of the invention have been shown anddescribed, numerous variations or alternate embodiments will occur tothose skilled in the art. Accordingly, it is intended that the inventionbe limited only in terms of the appended claims.

The invention claimed is:
 1. A method of prefabricating a syntheticsports field in a separate controlled facility for subsequentinstallation, comprising: providing a plurality of unprocessed strips ofsynthetic turf; visually marking lines on a substantially flat floor ofthe facility that corresponds to certain dimensions of the field,including a centerline; laying out a plurality of said unprocessedstrips on said floor back side up; aligning each of said plurality ofsaid unprocessed strips with respect to said centerline; marking saidcenterline onto said back side of each of said unprocessed strips;inlaying any necessary markings into each strip; rolling up each of saidstrips; transporting said rolls to an installation site; and installingsaid strips to form the synthetic field.
 2. The method of claim 1,wherein said step of inlaying includes cutting an opening in said stripthat matches said marking to be inserted into said strip; and securingsaid marking in said opening to said strip.
 3. The method of claim 2,wherein said markings are selected from the group consisting of: hashmarks, yard line numbers, or arrows.
 4. The method of claim 1, whereinsaid visible markings on said floor also correspond to a first set ofhash marks, a plurality of yard line numbers, a second set of hashmarks, and side lines.
 5. The method of claim 4, further comprising:cutting edges of said strip to match said sidelines, such that saidstrip is of the appropriate length.